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Old 06-14-2019   #1
 
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Red face 2019 Subaru Series.Grey BRZ Build Log

Hey all,

I've been sourcing parts for this install on these forums since December and have had great conversations with a select few members here.

I'm very much an amateur in this hobby so please feel free to call me out on anything! I've mentioned in previous posts how the only upgrade under my belt is a Hybid Audio 2-way component set and an Image Dynamics IDQ 12 that I installed about 75% of the way to completion. It sounded... okay.

Goals:
Keep weight additions relatively low.
Keep changes to the interior subtle...
Increase SQ 9000%
Make mistakes and learn!


Equipment:
AudioFrog GB 10/25/60
AudioTec Fischer Helix DSP.2
Stereo Integrity BM mk IV 12"
Arc Audio 600.4 (x2)
Arc Audio 1100.1
Stock HU



The beauty this is going into? A 2019 Subaru Series.Grey I picked up in November! My first new car!



First thing I started on was designing the subwoofer enclosure. Going with a shallow mount because of the work I've seen on these forums! Shout out to bertholomey and other BRZ owners.

TinkerCad is a little clunky to use for design... but it's free with an account and I got done with what I needed. Also, it might be a better tool to use when one hopes to 3D print their subwoofer enclosure.



I was open to the idea of putting the subwoofer in the passenger footwell... but my girlfriend at the time said she would refuse to ever get in this car again if there was even less room for her to sit. Lol.

So this design was with the backseat in mind.... Yes that's right. The subwoofer will be sitting in the back seat. Why not go IB?

Well, I'm into AutoX and my initial concerns were adding too much weight. So I thought it would be cool to have it removable in the back seat... like a child seat!

We'll see if I actually ever take it out of the backseat. Speaking of which... I think a tint might not be a bad idea...



So my grandfather was nice enough to let me use his workshop and completely cover it in MDF dust.

Making a true right angle(s) box is a pain. It came out alright though. The roundover bits were used on the top and bottom face... with a little bit too much taken off the top...


Nothing I can't fix with some further sanding.


Also, I used a MASSIVE 3/4 inch rabbiting bit for recessing the subwoofer... a bit. Don't worry! I calculated this into the final volume. IIRC, the final volume was around .55 ft^3.

And this picture shows a hint of things to come. The surprisingly rare painted subwoofer enclosure. (Why is everyone so quick to grab their carpet rolls?)


Also you can see the wood putty used to fill over the screw holes. I tossed around the idea of leaving them exposed but this was easier to pull off!


I wanted to do as much of this project by myself, but I cheated a bit.

As some of you know, chasingSQ's BRZ exploded in a fire-y death ball of flames. His misfortune (yeah right.. That new STI though...) led to me picking up the famous dash pods from bertholomey's build (Courtesy of Mark Worrell) as well as some A-pillars! A big thank you there as that has saved me quite a bit of time on this. (my first real car upgrade project)



More to come!


P.S. I'm much further along in the process now. So expect updates soon! Whenever I get time to upload.
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Old 06-14-2019   #2
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Looks like you're off to a great start! That's a sick stack of gear you've accumulated, and I've always had a fondness for the BRZ, definitely in for the build. I'm going with a very similar setup with AF drivers, Arc amps, and a Helix DSP.2 in my truck - it will definitely be an iterative process though.

I share your sentiment about the members here, I've been gathering ideas and soliciting input from people here for a few months now and everyone has been so helpful. It's cool to see people with similar interest sharing ideas and offering advice, especially to people new to this. I've definitely had fun so far, even though this place is hell on my wallet...
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Are you planning on doing any power mods to the car? Say maybe a turbo? It would forgo the need to be too concerned about weight.


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Old 06-14-2019   #4
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Quote:
Originally Posted by ajt976 View Post
Looks like you're off to a great start! That's a sick stack of gear you've accumulated, and I've always had a fondness for the BRZ, definitely in for the build. I'm going with a very similar setup with AF drivers, Arc amps, and a Helix DSP.2 in my truck - it will definitely be an iterative process though.

I share your sentiment about the members here, I've been gathering ideas and soliciting input from people here for a few months now and everyone has been so helpful. It's cool to see people with similar interest sharing ideas and offering advice, especially to people new to this. I've definitely had fun so far, even though this place is hell on my wallet...
Thanks, ajt! I agree especially about the kindness of the members here and the journey to the center of the earth... through my wallet.



Quote:
Are you planning on doing any power mods to the car? Say maybe a turbo? It would forgo the need to be too concerned about weight.
No turbos in the near future... although I was really considering a supercharger (sprintex or edelbrock).

More likely is a naturally aspirated tune and upgrades to keep me in possibly the street touring class in AutoX.

Added weight is still dead weight in a sense. Although, I'm only casually into AutoX so it's not a huge deal for this project. It's still my daily driver.
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Old 06-14-2019   #5
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

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Originally Posted by moodue View Post



Your enclosure is nice, but there isn't much left for the screws for the sub to bite into unless there is another layer going on top.

Quote:
Originally Posted by gijoe View Post
There is a difference between overkill and bad. Your idea isn't overkill, it's bad.
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Old 06-14-2019   #6
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

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Originally Posted by Niebur3 View Post
Your enclosure is nice, but there isn't much left for the screws for the sub to bite into unless there is another layer going on top.
Agreed. Don't make the mistake I made earlier in time.... much earlier... leave enough for the screws to bite into... Also, a thin layer of filler would help with the overall sound quality of the music being played.

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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Nice car. I agree about the box. When I build my boxes I double up the front baffle With two 3/4Ē pieces and cut one layer to the cutout size for the subwoofer and the second layer to the outside diameter of the subwoofer frame so the subwoofer sits flush and has meat for the mounting. Also, if you want lighter and stronger than MDF than consider using void free 11 ply birch plywood that comes in 60Ē x 60Ē sheets.

Youíre going to like those Frogs.

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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Thanks for the replies!

So... I'm really far into the painting process that I mentioned briefly with this subwoofer enclosure, including the top face.

T-nuts should do the trick, no?
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Old 06-14-2019   #9
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Quote:
Originally Posted by moodue View Post
Thanks for the replies!

So... I'm really far into the painting process that I mentioned briefly with this subwoofer enclosure, including the top face.

T-nuts should do the trick, no?
it appears you only have about 1/4" of baffle for the sub to be secured too?

If so that is not enough and you need to fix that before you proceed.

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Old 06-14-2019   #10
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

I'm trying to think of options I have without sacrificing the work I've done so far.

What about reinforcing the baffle from the inside? I lose a bit of volume, but it's still within the recommended range specified by Stereo Integrity.

edit: I just measured and it's almost at 3/8's of an inch.
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Old 06-14-2019   #11
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Quote:
Originally Posted by moodue View Post
I'm trying to think of options I have without sacrificing the work I've done so far.

What about reinforcing the baffle from the inside? I lose a bit of volume, but it's still within the recommended range specified by Stereo Integrity.

edit: I just measured and it's almost at 3/8's of an inch.
You could router out a reinforcement ring, cut it in half and glue it to the underside of the baffle. It would be an easy fix and not set you back with what you've done so far...

I would not be comfortable with just 3/8"s of mdf, good plywood maybe, but not mdf. With mdf, I would not settle for anything less than a full 3/4".

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Old 06-15-2019   #12
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Quote:
Originally Posted by moodue View Post
I'm trying to think of options I have without sacrificing the work I've done so far.

What about reinforcing the baffle from the inside? I lose a bit of volume, but it's still within the recommended range specified by Stereo Integrity.

edit: I just measured and it's almost at 3/8's of an inch.
Yep, 3/8" isn't near enough. Maybe for a small mid or tweeter, but not a sub.

David has a good idea.

JCsAudio - this is exactly what I do as well.

Quote:
Originally Posted by gijoe View Post
There is a difference between overkill and bad. Your idea isn't overkill, it's bad.
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Old 06-15-2019   #13
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

I love that color! That pic of the car is hot! Nice job! Iím so glad you could get an idea or two from my build, and Iím especially glad that a couple of those items could live on. I was stoked when Ian told me he found a good fella to pass those on to.

Good luck with your build - wonderful start so far!


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Old 06-15-2019   #14
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Quote:
Originally Posted by moodue View Post
Thanks for the replies!

So... I'm really far into the painting process that I mentioned briefly with this subwoofer enclosure, including the top face.

T-nuts should do the trick, no?
I would echo what others have said about the too-thin MDF, and adding additional material.

T-nuts are fine for plywood, however their teeth tend not to readily/properly penetrate MDF. I recommend hurricane nuts instead - just be sure to carefully drill holes of the same size as the O.D. of the part of the hurricane nut that is meant to fit snugly into the hole in the MDF. A tiny dab of GOOP (or other suitable adhesive) applied to each hurricane nut flange will provide additional assurance that they'll stay put whenever you might need to remove the sub.

https://www.parts-express.com/parts-...-pcs--081-1082

https://www.acehardware.com/departme...4aAv1tEALw_wcB
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Old 06-16-2019   #15
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Quote:
Originally Posted by Grinder View Post
I would echo what others have said about the too-thin MDF, and adding additional material.

T-nuts are fine for plywood, however their teeth tend not to readily/properly penetrate MDF. I recommend hurricane nuts instead - just be sure to carefully drill holes of the same size as the O.D. of the part of the hurricane nut that is meant to fit snugly into the hole in the MDF. A tiny dab of GOOP (or other suitable adhesive) applied to each hurricane nut flange will provide additional assurance that they'll stay put whenever you might need to remove the sub.

https://www.parts-express.com/parts-...-pcs--081-1082

https://www.acehardware.com/departme...4aAv1tEALw_wcB
Quote:
Originally Posted by DavidRam
You could router out a reinforcement ring, cut it in half and glue it to the underside of the baffle. It would be an easy fix and not set you back with what you've done so far...
Thanks for the suggestions! I have no problem making an excuse to visit the grandparent's again.. I love being overfed and then wandering off to the wood shop! (I think that's true no matter how old you get... the being fed part at least)


Quote:
Originally Posted by bertholomey
I love that color! That pic of the car is hot! Nice job! Iím so glad you could get an idea or two from my build, and Iím especially glad that a couple of those items could live on. I was stoked when Ian told me he found a good fella to pass those on to.

Good luck with your build - wonderful start so far!
Much appreciated to see in you in this thread!! I'm happy to find a nice home for these poor creatures.
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Old 06-16-2019   #16
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

I agree with DavidRam's idea. You may wish to use 1/2" ply or something else that is a little stronger than MDF for these parts.
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Old 06-16-2019   #17
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Yup I would cut a piece of wood 1/2" or 3/4" ply or MDF about 2" larger than the opening, and then cut it in half so you can fit it into the opening and glue it in place, then recut the hole using a flush trim bit router.

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Old 06-16-2019   #18
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

I would make the reinforcement piece a rectangle so it has as much mdf to grab onto as possible, since two of the sides are so close to the edge...

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Old 06-19-2019   #19
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

So I've taken the collective advice and made this reinforcement ring. I've used birch plywood. (not sure what void free is)

The two sides (of four) of the larger opening in the top face overlap the side wall. I haven't rigged it up yet, but the screws for the subwoofer may be partly in the side wall, and now partly in the birch baffle.

....not ideal. But I have the ring glued in place. (It needs a bit more sanding)





And now looking at this last picture I feel like there is a small space between the inner edge of the side wall and the ring that could be problematic........ feck.
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Hmmmm... (scratching head)

Seems like you should be able to position the sub so that the centerpoint between two mounting holes is aligned with the point at which the ring is thinnest (where the sub mounting flange would extend the farthest over the cabinet side panel), to avoid landing screws within or too near the problematic gap.
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Old 06-19-2019   #21
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Quote:
Originally Posted by moodue View Post

And now looking at this last picture I feel like there is a small space between the inner edge of the side wall and the ring that could be problematic........ feck.
That should not be a problem. But if you have OCD like most of us do run a bead of silicone to seal it.

As for the other thing regarding screwing down the woofer, i am confused as you what you are saying is the problem?

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Old 06-19-2019   #22
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Quote:
Originally Posted by moodue View Post
So I've taken the collective advice and made this reinforcement ring. I've used birch plywood. (not sure what void free is)

The two sides (of four) of the larger opening in the top face overlap the side wall. I haven't rigged it up yet, but the screws for the subwoofer may be partly in the side wall, and now partly in the birch baffle.

....not ideal. But I have the ring glued in place. (It needs a bit more sanding)


And now looking at this last picture I feel like there is a small space between the inner edge of the side wall and the ring that could be problematic........ feck.
I was hoping the ring would butt up to the side wall... Lol. It's definitely an improvement, though.

Hopefully, one of the screws doesn't end up in that gap. If you turn the sub a certain way, it shouldn't.

Btw, birch plywood is an excellent choice... Void free means it isn't supposed to have any air pockets in between the plies. The birch you got is the furniture grade, which is the prettiest, but not the strongest. Next time you want to get the 11 ply, it's much stronger.

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Last edited by DavidRam; 06-20-2019 at 08:16 AM..
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Old 06-19-2019   #23
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Well if it makes you feel any better I screwed up many boxes but like anything else I learned through that process and got better at it on each iteration. I think Iím on #8 now, lol. Just doing the whole wood building process itself is enjoyable for me though so itís like an invitation to keep doing more. I think you will be able to work with what youíve got. If you orientate the subwoofer holes just right so that the screws are in an optimal location relative to the pinched opening than you might be ok.

Sienna SB29 Focal PS165V Alpine SWS10 Mazda CX5 AF GB15 AF GB60 AF GB12 Ford F150 AF GB10 JLC5 Sundown SD310.
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Old 06-21-2019   #24
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

Quote:
Originally Posted by miniSQ
That should not be a problem. But if you have OCD like most of us do run a bead of silicone to seal it.

As for the other thing regarding screwing down the woofer, i am confused as you what you are saying is the problem?
The enclosure has such a small width on the top face that, depending on what angle I rotate the subwoofer, the mounting hole(s) could either be screwing into the side wall or the reinforcement ring and/or this little gap.

I'll just have to keep that in mind when I go to attach the subwoofer.

Quote:
Originally Posted by DavidRam
Btw, birch plywood is an excellent choice... Void free means it isn't supposed to have any air pockets in between the plies. The birch you got is the furniture grade, which is the prettiest, but not the strongest. Next time you want to get the 11 ply, it's much stronger.
Thanks for the info! I asked 2 people at Lowe's if they've heard of "void free" as a description for plywood and they looked at me like I was insane.


Also I just ran a bead of silicone over the inside edges of the subwoofer box. It's still drying.. I'm still coming down off the high caused by a not-so-well-ventilated garage.

I didn't, however, enclose the gap in silicone. Would there be advantages/disadvantages to doing that? Weighing the minute differences in volume after enclosing the gaps vs.... I don't know.. oddly shaped enclosures??


edit:
Quote:
Originally Posted by JCsAudio
doing the whole wood building process itself is enjoyable for me though so itís like an invitation to keep doing more
I couldn't agree more!

Appreciate the comments, yinz guys!
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Old 06-21-2019   #25
 
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Default Re: 2019 Subaru Series.Grey BRZ Build Log

I made some progress today! Also, of course, I have some time to update this log in a chronological fashion, as most of my work has been dragged out for soo loong.


So I was super thrilled to take this beautiful car (my first new car):



...and tear it a new one for sound deadoning.




I need to find more pictures of the work I did back here. But taking too many pictures wasn't very important at this moment because I was basically following along with tutorials found on different ft86 forums and such.

Essentially, I added some CLD to the rear fenders behind the rear speakers and layered MLV/CCF all the way across the back seat, down to (but not including) the floor.

Side note: I left the rear speakers in place. It's all I've had to listen to in my car for 3 months. They won't be connected once the AF's are up and running.




I have only ~30% coverage as far as Dynamat. It's leftover from my previous project.... as in, it's a decade old product. Used a little adhesive to help it stick.


There is quite a bit of coverage in the outer door card that you can't see in this picture.


Also, I'm unsure if there are or would be any noticeable difference (to me) in reverberation from 30% to, say, 80% coverage with some form of CLD.




Also added a small layer of butyl rope between the door frame and outer door skin like most brz/frs/ft86 specific tutorials suggest.


I used plenty of online sources to help with this part of the project:

nalc's post at FT86club forums
This imgur post. Poster credit?
And this forum, of course.




Here is my custom MLV + CCF sound deadoning layer.. before I have the opportunity to rip/poke/gnaw at it with pliers/utility knife/you name it.



You'll notice the door panel clips are just barely poking through. This part of the project will haunt my dreams. And it still does to this day. I'm considering re-sound deadening.. maybe with a thinner product.

I'm unsure why I didn't just buy a product designed for this. I thought I would be saving so much money by just making this sheet myself. Simply used contact adhesive and a roller.


I'll probably be taking the door panels off shortly and I'll be sure to get a picture of the final product. (A little annoying to get out the phone/camera all the time when you are in the zone )


Picked up these bad boys from carstereoadapters.com Very friendly, helpful dude running this.


I was going to make these myself, but simply sourcing a thick sheet (or even scraps) of PVC/HDPE was more expensive then what he charges for a finished product, specific to your vehicle / drivers. Not an advertisement, but it was an easy decision. [wait.. that's like a cliche commercial saying ]

Made use of the t-nuts to hold the GB60's in place. (Sorry for not enough pictures)


I followed mostly standard advice found through the forums. Weather stripping/CCF directly behind the door speakers on the outer wall. Stacked stripping/CCF layers to form rings behind and in front of speaker baffle. I'm kinda eyeing up the CCF rings that, I believe, SoundSkins just recently released? IIRC, the rings they had at the time of installation were OCF and that was a little pointless I guess? I could be mistaken though.





I used this opportunity to run the speaker wires for the Audiofrog's up front. Okay.... I realized after I cut and ran this speaker wire that I went way overboard on the wire gauge. This is KnuKoncepts 10awg.

This was sure to be a pain in the ass in terms of connecting these washer/dryer-electrical-cord sized wires to the GB lineup (subwoofer excluded.. obviously).

These wires got some lovin before being tucked away. A bit messy in this picture. (You're going to be seeing a lot more of this smiley)



I am slightly regretting not covering these wires with a loom of some sort. I may go back and do that as I have a pretty blue/black loom I've used under the hood.


Supposed to get some sun tomorrow... TIME TO GET TO WORK!
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